Systems, devices, and methods to detect pipe with a gripperhead

Abstract

The systems, devices, and methods described herein relate to tubular detection on a gripperhead system for a drilling rig. The gripperhead system includes a grabber and a gripper each having first and second grabber arm and pistons connected to the first and second arms. Each arm may also include an inwardly facing gripping surface forming at least a portion of a chamber sized to receive a portion of a cylindrical tubular. One or more sensors may be disposed on the gripperhead system, including proximity sensors disposed on the arms, inductive sensors disposed within the pistons, and ultrasonic sensors disposed on other features of gripperhead system. The one or more sensors may be configured to determine the position of the tubular in relation to the arms, measure the size of the tubular, measure the compression force of the grabber, and ensure that the tubular is secured within the grabber.

What is claimed is: 
     
       1. An apparatus for grasping tubulars, comprising:
 a grabber assembly including a first grabber arm and a second opposing grabber arm, each grabber arm having an inwardly facing gripping surface that forms at least a portion of a chamber sized to receive a portion of a cylindrical tubular, wherein the grabber is arranged so that each of the first grabber arm and the second grabber arm are sized to fit between tubulars in adjacent rows of a fingerboard and the first grabber arm and the second grabber arm are laterally adjustable in a lateral direction to change a distance between the first grabber arm and the second grabber arm, and wherein the first grabber arm is disposed relative to the second grabber arm so the first grabber arm and the second grabber arm are adjustable in a direction transverse to the lateral direction, and the grabber assembly is arranged to manipulate a tubular into the chamber so that a gripper can grip the tubular; 
 a set of sensors comprising a first sensor disposed on the grabber assembly and configured to determine a position of the cylindrical tubular within the chamber; and 
 a linear actuator connected to the first and second grabber arms, the linear actuator configured to control actuation of the grabber assembly, wherein the first sensor is disposed within the linear actuator and configured to verify that a tubular held by the grabber is aligned with an axis of the chamber so that the gripper can grip the tubular. 
 
     
     
       2. The apparatus of  claim 1 , wherein the first sensor is configured to determine the distance between the first grabber arm and the second opposing grabber arm. 
     
     
       3. The apparatus of  claim 1 , wherein the first sensor is an inductive sensor. 
     
     
       4. The apparatus of  claim 1 , wherein the first sensor is a linear variable differential transducer (LVDT). 
     
     
       5. The apparatus of  claim 1 , wherein the set of sensors comprises a second sensor disposed on the first grabber arm. 
     
     
       6. The apparatus of  claim 5 , wherein the second sensor is a proximity sensor. 
     
     
       7. The apparatus of  claim 1 , further comprising a manipulator arm, wherein the set of sensors comprises a third sensor disposed on the manipulator arm. 
     
     
       8. The apparatus of  claim 7 , wherein the third sensor is an ultrasonic sensor. 
     
     
       9. The apparatus of  claim 7 , further comprising a controller in communication with the set of sensors, the controller configured to receive input from the first and third sensors and determine the position of the cylindrical tubular within the chamber based on the input from the first and third sensors. 
     
     
       10. The apparatus of  claim 1 , further comprising a first and a second gripper arm, with each gripper arm being displaceable in a direction along a first axis that is transverse to a longitudinal axis between a retracted position and an extended position. 
     
     
       11. The apparatus of  claim 10 , further comprising:
 a centralizer arranged to manipulate a tubular held by the first and second grabber arms or the first and second gripper arms, the centralizer comprising a first centering arm and an opposing second centering arm, each centering arm positioned to pivot about a third and fourth pivot point, respectively, and between an open position sized to permit a portion of a cylindrical tubular to enter the chamber and a closed position sized to secure a portion of a cylindrical tubular in the chamber. 
 
     
     
       12. A modular gripperhead for use with a drilling rig apparatus, the modular gripperhead comprising:
 a grabber comprising a first grabber arm, a second opposing grabber arm, and a first linear actuator connected to the first and second grabber arms, each grabber arm having an inwardly facing gripping surface that forms at least a portion of a chamber sized to receive a portion of a cylindrical tubular, wherein the portion of the chamber has a longitudinal axis, wherein the grabber is arranged so that each of the first grabber arm and the second grabber arm are sized to fit between tubulars in adjacent rows of a fingerboard disposed on the drilling rig apparatus and the first grabber arm and the second grabber arm are laterally adjustable in a lateral direction to change a distance between the first grabber arm and the second grabber arm, and wherein the first grabber arm is disposed relative to the second grabber arm so the first grabber arm and the second grabber arm are adjustable in a direction transverse to the lateral direction; 
 a gripper comprising a first gripper arm and a second opposing gripper arm, wherein each of the first and second gripper arms is pivotable about a first and second pivot point, respectively, and between an open position sized to permit a portion of the cylindrical tubular to enter the chamber and a closed position sized to secure a portion of the cylindrical tubular in the chamber, 
 wherein the grabber is arranged to manipulate a tubular into the chamber so that the gripper can grip the tubular; and 
 a first sensor disposed on the grabber and configured to determine the position of the cylindrical tubular within the chamber and verify that a tubular held by the grabber is aligned with an axis of the chamber so that the gripper can grip the tubular. 
 
     
     
       13. The modular gripperhead of  claim 12 , wherein the first sensor is an inductive sensor. 
     
     
       14. The modular gripperhead of  claim 12 , where in the first sensor is a linear variable differential transducer (LVDT). 
     
     
       15. The modular gripperhead of  claim 12 , wherein the first sensor is configured to measure a distance between the first and second gripper arms. 
     
     
       16. The modular gripperhead of  claim 12 , further comprising a second sensor disposed on one of the first and second gripper arms. 
     
     
       17. The modular gripperhead of  claim 16 , wherein the second sensor is a proximity sensor configured to detect whether the first or second grabber arm is in contact with the cylindrical tubular. 
     
     
       18. The modular gripperhead of  claim 12 ,
 wherein each of the first and second grabber arms is hydraulically actuated; 
 wherein each of the first gripper arm and the second opposing gripper arms is hydraulically actuated;
 wherein the modular gripperhead also comprises a hydraulic manifold assembly that is configured to actuate each of the first grabber arm, the second grabber arm, the first gripper arm, and the second opposing gripper arm; 
 wherein the hydraulic manifold assembly comprises a plurality of quick connect couplers that corresponds with each of the first and second grabber arms and the first and second gripper arms; and 
 wherein the plurality of quick connect couplers are on a top surface of the hydraulic manifold assembly. 
 
 
     
     
       19. The modular gripperhead of  claim 12 , wherein the modular gripperhead comprises an electrical connector configured to connect the modular gripperhead to a power source. 
     
     
       20. The modular gripperhead of  claim 12 , wherein the gripper is configured to apply a sufficient force to the cylindrical tubular to hoist and otherwise manipulate the cylindrical tubular. 
     
     
       21. A method of manipulating a tubular, the method comprising:
 positioning a grabber assembly gripperhead in proximity to the tubular, the grabber assembly comprising a linear actuator connected to a first grabber arm and a second opposing grabber arm, each grabber arm having an inwardly facing gripping surface that forms at least a portion of a generally cylindrically chamber; wherein the portion of the generally cylindrically chamber has a longitudinal axis; 
 determining, with a set of sensors disposed on the grabber assembly, a position of the tubular within the cylindrical chamber; 
 closing the first and second grabber arms to secure the tubular between the first and second grabber arms; and 
 calculating, with a controller connected to the set of sensors, a distance between the first grabber arm and the second opposing grabber arm. 
 
     
     
       22. The method of  claim 21 , further comprising calculating, with the controller, a size of a tubular positioned within the generally cylindrical chamber based on the calculation of the distance between the first grabber arm and the second opposing grabber arm. 
     
     
       23. The method of  claim 21 , further comprising verifying, with a proximity sensor of the set of sensors, that the tubular is secured by the grabber assembly. 
     
     
       24. The method of  claim 21 , wherein the positioning a grabber assembly in proximity to the tubular includes measuring, with one or more ultrasonic sensors, the position of a tubular in front of the grabber assembly. 
     
     
       25. A method of manipulating a tubular, the method comprising:
 positioning a grabber assembly gripperhead in proximity to the tubular, the grabber assembly comprising a linear actuator connected to a first grabber arm and a second opposing grabber arm, each grabber arm having an inwardly facing gripping surface that forms at least a portion of a generally cylindrically chamber, wherein the portion of the generally cylindrically chamber has a longitudinal axis; 
 determining, with a set of sensors disposed on the grabber assembly, a position of the tubular within the cylindrical chamber; 
 closing the first and second grabber arms to secure the tubular between the first and second grabber arms; and 
 measuring, with the set of sensors, a deformation of the tubular after closing the first and second grabber arms to secure the tubular between the first and second grabber arms. 
 
     
     
       26. A method of manipulating a tubular on a drilling rig apparatus, the method comprising:
 positioning a grabber assembly in proximity to the tubular, the grabber assembly comprising a linear actuator connected to a first grabber arm and a second opposing grabber arm, each grabber arm having an inwardly facing gripping surface that forms at least a portion of a generally cylindrically chamber; wherein the portion of the generally cylindrically chamber has a longitudinal axis alignable with a tubular, wherein the grabber assembly is arranged so that the first grabber arm and the second grabber arm are sized to fit between tubulars in adjacent rows of a fingerboard of the drilling rig apparatus and the first grabber arm and the second grabber arm are laterally adjustable in a lateral direction to change a distance between the first grabber arm and the second grabber arm, and wherein the first grabber arm is disposed relative to the second grabber arm so the first grabber arm and the second grabber arm are adjustable in a direction transverse to the lateral direction, and the grabber assembly is arranged to manipulate a tubular into the chamber so that a gripper can grip the tubular; 
 determining, with a set of sensors disposed on the grabber assembly, a position of the tubular within the cylindrical chamber and verifying that a tubular held by the grabber is aligned with an axis of the chamber so that the gripper can grip the tubular; 
 closing the first and second grabber arms to secure the tubular between the first and second grabber arms; and 
 measuring, with the set of sensors, a pressure measurement to avoid crushing the tubular. 
 
     
     
       27. The method of  claim 26 , further comprising verifying, with the pressure measurement, that the tubular is secured by the grabber assembly.